Conductor assembly for a power distribution system

ABSTRACT

An electrical conductor assembly for use in a power distribution assembly includes an electrical conductor. A casing covers at least a portion of the electrical conductor. The casing insulates the at least a portion of the electrical conductor.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/927,035, filed Oct. 28, 2019, which is hereby incorporatedby reference in its entirety.

FIELD

The present disclosure generally relates to a power distribution system,and more particularly to a flexible conductor chassis assembly for apower distribution system.

BACKGROUND

Electrical apparatus, such as electrical switching apparatus orelectrical meters used in power distribution systems, are often mountedon or within an electrical enclosure (e.g., without limitation, a panelboard; a load center; a meter breaker panel) either individually or incombination with other electrical meters or switchgear (e.g., withoutlimitation, circuit switching devices and circuit interrupters such ascircuit breakers, contactors, motor starters, motor controllers andother load controllers). The electrical enclosure is typically coupledto and supported by a structure such as, for example, a wall of abuilding, and includes a number of electrical bus members.

In industrial applications the available space is limited. Therefore, inorder to maximize the space for process equipment and minimize theinstallation cost, it is beneficial to design power distributionequipment, such as panel boards, in the smallest possible footprint. Intypical residential and commercial applications the circuit breakershave a consistent pole to pole spacing since typically theelectro-mechanical device created for 1 pole is equally replicated when2, 3 or more are needed. In hazardous locations, those same circuitbreakers are enclosed or encapsulated to make them suitable forcombustible atmospheres. In doing so, the enclosure footprint around theindividual circuit breakers is minimized to reduce the effects of aninternal explosion. As a result, the pole to pole spacing of a hazardousarea circuit breaker may not be in consistent pole to pole spacingincrements like an ordinary breaker and therefore flexible bus barscreate significant advantages in making breaker panel systems with anybreaker, especially hazardous area rated breakers or cases whendifferent manufacturer's designs are used within the same panel, wherethe pole to pole spacing is inconsistent. Also, panel boards typicallyinclude at least one rigid bus bar acting as an electrical conductor fordelivering electricity to the electrical switching apparatus. The rigidnature of the bus bar restricts the positioning of the switchingapparatus within the panel board and the type of switching apparatusthat can be used within the panel board. Typical rigid bus bars includemultiple connection points which can be expensive to manufacture andincrease assembly time. Further, joints between two attached conductorscan increase electrical resistance creating thermal hot spots within theenclosure that may lead to increased frequency and cost of maintenance.For example, when a breaker is bolted directly to a bus bar there may bea relatively high resistance across that joint connection. This is shownin FIG. 1A where conductors 1A include elongate rigid bus bar sections3A having rigid branch conductors 5A separately attached to the bus barsections by fasteners 7A. This system has an increased electricalresistance thereby creating thermal resistance leading to increasedtemperature or hot spots further leading to increased frequency and costof maintenance. Also, the joints may loosen as a result of temperaturecycling increasing the resistance and temperature rise at the connectionpoint. Loose connections may also lead to arcing which could be a sourceof ignition in a hazardous/combustible atmosphere. Panel boards can alsohave exposed live conductors which are a shock hazard to operators andmaintenance workers.

An example of another rigid conductor assembly of the prior art is shownin FIG. 1B. Each conductor 1B includes an elongate rigid central bus barportion 3B and a plurality of rigid branch sections 5B extendinglaterally from the central bus bar portion. The branch sections 5B arebent to accommodate stacking multiple conductor assemblies on top ofeach other for distributing multiple phases of electricity. This system,however, is only configured to accommodate one switchgear arrangementand limited types of switchgears. Additionally, the bus bar in FIG. 1Bis arranged for breakers with consistent pole to pole spacing. FIG. 1Bis of a bus bar that is specifically designed for breakers that do nothave consistent pole to pole spacing. However, as a result and becauseof its inherent rigidity, the bus bar must be replaced should a changein breaker be needed. It also must have multiple sections splicedtogether should breakers of different pole quantities be required in thesame system. Thus, this bus bar arrangement requires a unique bus barassembly for each breaker system layout required. Therefore, should theelectrical system require a new breaker layout for any reason during thelife of the system, complete replacement of the bus bar assembly isrequired increasing the cost and complicating the planning required forthese maintenance events due to component availability. Further, theselogistical challenges impact the availability to manufacture andinventory carrying costs of products yet to be configured for customerorders.

SUMMARY

In one aspect, an electrical conductor assembly for use in a powerdistribution assembly generally comprises an electrical conductor. Acasing covers at least a portion of the electrical conductor. The casinginsulates said at least a portion of the electrical conductor.

In another aspect, a power distribution assembly generally comprises anenclosure and a flexible electrical conductor disposed in the enclosure.The flexible electrical conductor comprises a main conductor portioncomprising electrically conductive material and a plurality of branchmembers comprising electrically conductive material extending laterallyfrom the main conductor portion. Each branch member is selectivelybendable and configured for electrical connection to an electricalswitching apparatus. A plurality of casings cover portions of theflexible electrical conductor. Each casing insulates a portion of theflexible electrical conductor.

In yet another aspect, a casing for use with an electrical conductorgenerally comprises a first casing member configured to cover at least afirst portion of the electrical conductor. A second casing member isattachable to the first casing member and configured to cover at least asecond portion of the electrical conductor. The first and second casingmembers insulate said at least the first and second portions of theelectrical conductor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective of a prior art conductor assembly;

FIG. 1B is a perspective of another prior art conductor assembly;

FIG. 2A is a perspective of a power distribution assembly including anenclosure;

FIG. 2B is a front view of the power distribution assembly in FIG. 2Awith a door and internal cover removed showing conductors within theenclosure and connected to multiple switching apparatuses;

FIG. 2C is a front view of the power distribution assembly in FIG. 2Awith the door and internal cover removed showing conductors within theenclosure connected to multiple switching apparatuses and folded backinto a mounting plate of the enclosure;

FIG. 3 is a perspective of a conductor assembly showing branch membersof a conductor of the conductor assembly in a bent configuration forbeing attached to switching apparatuses;

FIG. 4 is a front view of a fragmentary portion of the conductor;

FIG. 5 is a perspective of the conductor in the bent configuration;

FIG. 6 is a perspective of the conductor assembly in FIG. 3 showing thebranch members in a folded configuration;

FIG. 7 is a perspective of the conductor in the folded configuration;

FIG. 8 is a perspective of a casing of the conductor assembly;

FIG. 9 is a front perspective of a casing member of the casing;

FIG. 10 is a rear perspective of the casing member;

FIG. 11 is front view of the casing member; and

FIG. 12 is a rear review of the casing member.

Corresponding reference characters indicate corresponding partsthroughout the drawings.

DETAILED DESCRIPTION

Referring to FIGS. 2A-3 , one embodiment of a power distributionassembly is generally indicated at 20. The power distribution assembly20 includes an electrical enclosure generally indicated at 22. Theenclosure 22 includes a housing 24 which can be made from any suitablematerial such as stainless steel, plastic, etc. The housing 24 caninclude a door or cover 25 or any other structure for providing accessto the internal components of the enclosure 22. The housing 24 may alsoinclude an internal cover or “dead front” cover 27 within the interiorof the housing. The “dead front” cover 27 has cutouts for receivingswitching apparatuses 32. An electrical conductor assembly 26 is housedwithin the enclosure 22 and comprises a plurality of electricalconductors 30. The electrical conductors 30 are separated from eachother by casings 33 which mount the conductors in the enclosure and atleast partially cover the conductors to ensure that the properelectrical spacing is maintained within the assembly 26. Thus, thecasings 33 also insulate the conductors 30. In the illustratedembodiment, multiple conductors 30 and multiple casings 33 form theconduct assembly 26. However, a single electrical conductor 30 and asingle casing 33 may also be considered an electrical conductorassembly.

Each conductor 30 of the conductor assembly 26 is configured toelectrically connect to multiple electrical switching apparatuses 32such as, for example and without limitation, circuit breakers. In theillustrated embodiment, the multiple conductors 30 facilitatedistributing multiple phases of electricity. While the switchingapparatus 32 are described as circuit breakers, any known or suitabletype and/or configuration of electrical switching apparatus could beemployed, without departing from the scope of the present disclosure. Tothat extent, the conductor 30 enables the combination of differentcircuit breaker manufacturer's equipment having different structureswithin a single system. This combination of different circuit breakerswould not be possible in a rigid bus bar system. For this reason, it isstandard for panel board systems incorporating rigid bus bars to specifya single suitable switching apparatus manufacturer for use in thesystem. The conductor assembly 26 of the current disclosure alleviatesthe needs for such a restriction. In one embodiment, the electricalconductor 30 is an electrical bus which carries or transfers voltage,current, or power.

As employed herein, the term “enclosure” refers to any suitablestructure for housing an electrical switching apparatus (e.g., withoutlimitation, circuit switching devices and circuit interrupters such ascircuit breakers, contactors, motor starters, motor controllers andother load controllers) and expressly includes, without limitation,panel boards, load centers and switchgear cabinets, as well as otherstructures or compartments which are covered with a panel, such as, forexample and without limitation, in a prepared opening in the wall of abuilding, in a piece of machinery, or in a vehicle.

As employed herein, the statement that two or more parts are “attached”together shall mean that the parts are joined together either directlyor joined through one or more intermediate parts.

As employed herein the term “fastener” refers to any suitable connectingor tightening mechanism including, but not limited to, rivets, screws,bolts, and the combinations of bolts and nuts (e.g., without limitation,lock nuts) and bolts, washers and nuts.

Referring to FIG. 4 , each electrical conductor 30 comprises a partiallyflexible electrical conductor. In the illustrated embodiment, eachconductor 30 includes an elongate rigid central conductor portion 35, anelongate flexible central conductor portion 34 attached to the rigidconductor portion, and a plurality of elongate flexible branch members36 attached to the rigid central conductor portion 35 and extendinglaterally outward from the rigid central conductor portion. The branchmembers 36 may be attached to the rigid conductor portion 35 by anysuitable means. For example, threaded fasteners, rivets, welding,adhesive, clamps, or any other suitable attachment mechanism may be usedto attach the branch members 36 to the rigid conductor portion 35. Inthe illustrated embodiment, welds 37 attach the branch members 36 to therigid central conductor portion 35. Thus, in one embodiment, theflexible branch members 36 are formed separately from the centralconductor portion 35. Alternatively, the casing 33 can be used to attachthe branch members 36 and the flexible central conductor portion 34 tothe central conductor portion 35, as will be explained in greater detailbelow. Also, the branch members 36 could be formed integrally with thecentral conductor portion 35. Each branch member 36 is configured forelectrically connecting to a switching apparatus 32. Therefore, eachconductor 30 provides a flexible electrically conductive chassis formaking multiple electrical connections to different switchingapparatuses 32. The elongate rigid central conductor portion 35 and theelongate flexible central conductor portion 34 may be broadly considereda main conductor portion. Alternatively, just the rigid centralconductor portion 35 may be considered a main conductor portion.Additionally, the entire central conductor portion may be flexible.

The rigid conductor portion 35, flexible conductor portion 34, and eachflexible branch member 36 individually comprise generally rectangularcomponents. Other configurations of the conductor portions 34, 35 andbranch members 36 are also envisioned without departing from the scopeof the disclosure. In FIG. 4 there are shown three (3) branch members 36extending perpendicularly outwardly from opposite sides of the rigidcentral conductor portion 35, and in FIG. 5 , eleven (11) branch members36 are shown. It will be understood that other numbers of branch members36 are also envisioned. Further, the central conductor portion 34 can beshortened or lengthened to accommodate the desired number of branchmembers 36. Also, while each branch member 36 is shown as extendinglaterally from both sides of the rigid conductor portion 35, one or morebranch members could be separated into two separate branch members andsuitably attached to opposite sides of the rigid conductor portion. Asillustrated, the sections of the branch members 36 on one side of thecentral conductor portion 34 are aligned along a longitudinal axis ofthe central conductor portion with a section of the branch member on theopposite side of the central conductor portion. Alternatively, one ormore branch members could be staggered or off-set along a longitudinalaxis of the rigid central conductor portion 35 relative to the branchmembers on the opposite side of the rigid central conductor portion.

The rigid central conductor portion 35 may comprise a standard copperbus bar member, and the flexible central conductor portion 34 and thebranch members 36 may each comprise multiple layers of laminatedconductive material such as copper, aluminum, or any other suitableelectrically conductive material. The layers of conductive material mayalso be plated with the same or another electrically conductive materialsuch as tin, silver, aluminum, or any other suitably conductivecoatings. It will be understood that the central conductor portions 34,35 and branch members 36 can have over configurations without departingfrom the scope of the disclosure. Insulation covers or sleeves 40surround the flexible central conductor portions 34 and the flexiblebranch members 36 of the conductors 30. In the illustrated embodiment,the covers 40 surround a substantial portion of the flexible centralconductor portion 34 and branch members 36 but do not surround theirentireties. As shown, the covers 40 surround substantially an entiretyof the flexible central conductor portions 34 but does not cover freeend sections 42 (FIG. 5 ) of the flexible central conductor portions.Similarly, the covers 40 surround substantially an entirety of thebranch members 36 but do not cover free end sections 44 of the branchmembers. The exposed free end sections 42, 44 are configured forelectrically connecting with the switching apparatuses 32. For example,main circuit breakers may be electrically connected to the free endsections 42 of the flexible central conductor portions 34, and branchcircuit breakers may be electrically connected to the free end sections44 of the branch members 36. Referring to FIG. 4 , a cap 50 may coverthe free end sections 44 of at least some of the branch members 36. Forexample, a cap 50 may be placed over the free end sections 44 of thebranch members 36 that are not connected to a switching apparatus 32.The covers 40 and caps 50 may be formed by overmold or by extrusion. Inone embodiment, the cover 40 surrounding the central conductor portion34 of the conductor 30 is overmolded on the conductor, and the coverssurrounding the branch members 36 are extruded. However, all the covers40 may be overmolded or extruded without departing from the scope of thedisclosure. Suitable materials for forming the cover 40 include, withoutlimitation, thermoplastics including polyvinyl chloride (PVC) andsanipreen.

Alternatively, while the insulation material of the cover 40 is shown ascovering a portion, but not all, of the electrically conductive materialof the conductor 30, the insulation material of the cover 40 may extendover an entirety of the central conductor portion 34 and/or one or morebranch members 36. In this instance, a section of the cover 40 may beremoved from the central conductor portion 34 and/or one or more branchmembers 36 to expose the electrically conductive material for connectionto a switching apparatus 32.

The branch members 36 are selectively bendable such that the branchmembers can be bent in a first configuration to accommodate a firstswitching apparatus arrangement, and subsequently bent in a second ormore configurations, different from the first configuration, toaccommodate a second or more switching apparatus arrangements. Thus, thebranch members 36 are elastically deformable. The central conductorportion 34 may also be elastically deformable. The conductor 30,including the central conductor portion 34 and the branch members 36,can be bent or folded about multiple axes and/or twisted about an axisto configure the conductor in a desired configuration for a particularuse. The bending, folding, and or twisting can be done by hand by an enduser. Thus, the conductor 30 can be configured as needed to accommodateswitching apparatuses 32 of different sizes and shapes. Moreover, aswill be explained in greater detail below, the flexible nature of theconductor 30 allows the switching apparatuses 32 to be properlypositioned when multiple conductors are stacked on top of each otherwithin the enclosure 22 for distributing multiple phases of electricity.

Referring to FIGS. 6 and 7 , branch members 36 which are not connectedto a switching apparatus 32 may be bent or otherwise moved out of thearea of the other branch members to provide additional space within theenclosure for the switching apparatuses, and for further insulating thebare conductor end from a service person. As shown in the illustratedembodiment, unused branch members 36 can be bent back towards the casing33 and the free end sections 44 can be inserted into the casing toshield the free end of the branch member, as will be explained ingreater detail below.

As shown in FIGS. 2B, 3, and 6 , the flexible and insulatedconfiguration of the conductor assembly 26 also facilitates stacking twoor more conductors on top of each other to configure the powerdistribution assembly for delivering multiple phases of electricity. Inthis arrangement, a first conductor 30 mounted within a first casing 33could be configured to distribute a first phase of electricity to afirst set of switching apparatus 32 in the enclosure 22, a secondconductor 30 mounted within a second casing 33 and placed generally overthe first conductor could be configured to distribute a second phase ofelectricity to a second set of switching apparatus 32 in the enclosure,a third conductor 30 mounted within a third casing 33 and placedgenerally over the second conductor could be configured to distribute athird phase of electricity to a third set of switching apparatus 32 inthe enclosure, and so on. With the conductors 30 stacked on top of eachother, the branch members 36 may not align perfectly with a respectiveswitching apparatus 32. This is particularly the case for multiple polecircuit breakers 32. FIG. 2B identifies a 2 pole circuit breakers 32_((2p)) and a 3 pole circuit breaker 32 _((3p)). The flexibleconfiguration of the conductor 30, and the branch members 36 inparticular, allows for a sound electrical connection to still be madewith the switching apparatus, including the multiple pole circuitbreakers 32 _((2p)), 32 _((3p)), by bending, twisting, or otherwisemanipulating the branch member to connect with the switching apparatus.The casings 33 surrounding each of the conductors 30 insulates eachconductor from any other conductor within the enclosure 22 allowing theconductors 30 to be placed on top of each other without having anyinterference between the phases.

Referring to FIGS. 3 and 8-12 , each casing 33 covers a portion of oneof the conductors 30 to cover the exposed conductor sections (i.e.,sections not covered by a cover 40) of the conductor creating a touchsafe barrier over the conductor so that the enclosure 22 can be safelyaccessed by a service person. The casings 33 also space the conductor 30from the other conductors in the enclosure 22 so that there is noelectrical interference between the conductors in the conductor assembly26. Each casing 33 comprises a first casing member 41 and a secondcasing member 41 attachable to the first casing member. The casingmembers 41 are configured such that a section of a conductor 30 can bedisposed between the casing members and the casing members can beattached to each other to cover the section of the conductor.Additionally, a fastener (not shown) may extend through the casing 33and engage a back surface of the enclosure 22 to mount the casing 33 andconductor 30 in the enclosure. In one embodiment, the casing members 41are generally rigid structures.

The first and second casing members 41 are identical in structure andeach comprise a generally elongate plate-like configuration. Each casingmember 41 comprises a body 43 including a main body section 45 and anextension section 47 extending from a bottom end of the main bodysection. The main body section 45 has an elongate octagonal shape.However other shapes and configurations are within the scope of thedisclosure. The extension section 47 comprises a first extension portion49 and a second extension portion 51 extending from the first extensionportion. The second extension portion 51 is stepped down from the firstextension portion 49 forming a shoulder 53 between the extensionportions. The body 43 including the main body section 45 and extensionsection 47 has an inner surface 55 and an outer surface 57. Holes 59extend through the body 43 from the outer surface 57 to the innersurface 55. The holes 59 permit fasteners to extend through the casing33 to attach the casing to the enclosure 22. In the illustratedembodiment, there are four (4) holes 59. However, there could be anynumber of holes without departing from the scope of the disclosure.Additionally, the holes could be omitted and the casing could be mountedto the enclosure by other means.

The body 43 of each casing member 41 defines hole alignment structuredisposed around each hole 59 at the inner and outer surfaces 55, 57. Afirst hole alignment structure 61 is located on the outer surface 57 ofthe casing members 41 and is disposed around the top two holes 59. Thefirst hole alignment structure 61 includes an annular projection 63extending outward from the outer surface 57 and configuring the top twoholes 59 as counterbore holes on the outer surface of the casing member41. Thus, the first hole alignment structure 61 includes a flat-bottomedhole section 65 that enlarges another coaxial hole section. A secondhole alignment structure 67 is located on the outer surface 57 of thecasing members 41 and is disposed around the bottom two holes 59. Thesecond hole alignment structure 67 includes an annular projection 69extending outward from the outer surface 57 and an annular recess 71 inthe outer surface disposed around the annular projection 69. The secondhole alignment structure 67, and in particular the annular projection69, also configures the bottom two holes 59 as counterbore holes on theouter surface of the casing member 41. A third hole alignment structure73 is located on the inner surface 55 of the casing members 41 and isdisposed around the left two holes 59 (as viewed from the outer surface57) in the casing member. The third hole alignment structure 73 includesan annular projection 75 extending inward from the inner surface 55 andan annular recess 77 in the inner surface and disposed around theannular projection 75. The third hole alignment structure 73, and inparticular the annular projection 75, configures the left two holes 59(as viewed from the outer surface 57) as counterbore holes on the innersurface of the casing member 41. A fourth hole alignment structure 79 islocated on the inner surface 55 of the casing members 41 and is disposedaround the right two holes 59 (as viewed from the outer surface 57) inthe casing member 41. The fourth hole alignment structure 79 includes afirst annular projection 81 extending inward from the inner surface 55and a second annular projection 83 extending inward from the innersurface and disposed around the first annular projection 81 forming anannular floor 85 between the two projections. It will be understood thatthe hole alignment structures could have other configurations withoutdeparting from the scope of the disclosure. Moreover, the hole alignmentstructures could be omitted.

Referring to FIGS. 10 and 12 , a longitudinal channel 91 is formed inthe inner surface 55 of the body 43 and extends longitudinally along thebody between opposite ends of the body. The longitudinal channel 91 issized and shaped to receive the central conductor portion 35 ofconductor 30. For example, a width of the longitudinal channel 91 may beslightly larger than a width of the central conductor portion 35 so thatthe central conductor portion is held securely within the channel. Thelongitudinal channel 91 has a first section 93 extending from near a topend of the casing member 41 toward a bottom end of the casing member, asecond section 95 extending from the bottom end of the casing membertoward the top end of the casing member, and a third section 97 betweenthe first and second sections. The first section 93 is recessed belowthe second section such that the section of the longitudinal channel 91at the first section is deeper than the section of the longitudinalchannel at the second section. As will be explained in greater detailbelow, the recessed first section 93 provides clearance for the centralconductor portion 35 and the extension sections 47 of the casing members41 of another casing 33 when multiple casings are coupled together in alinear arrangement.

A transverse channel 99 is formed in the inner surface 55 of the body 43and extends transversely through the body between opposite sides of thebody. The transverse channel 99 is sized and shaped to receive a branchmember 36 of the conductor 30. For example, a width of the transversechannel 99 may be slightly larger than a width of the branch member 36so that the branch member is held securely within the channel. Clamps101 are disposed in the transverse channel 99 on opposite sides of thelongitudinal channel 91. The clamps 101 are configured to engage thebranch members 36, and in particular the covers 40 on the branchmembers, to prevent the covers from sliding off. In the illustratedembodiment, the clamps 101 comprise bars that extend the entire width ofthe transverse channel 99. However, the clamps 101 could have otherconfigurations without departing from the scope of the disclosure.

Referring to FIGS. 8-10 , clip arms 103 extend from a right side of thebody 43 (as viewed from the front of the casing member 41) toward theinner surface 55 of the casing member 41. Each clip arm 103 comprises anarm member 105 and a catch 107 that extends laterally from the armmember 105. Slots 109 are formed in the left side of the body 43 (asviewed from the front of the casing member 41) and are sized and shapedto receive the clip arms 103 of another casing member 41 for attachingthe casing members together to form a casing 33. Each catch 107 has anangled surface 111 which is configured to engage a ramp surface 113 inthe slots 109 when the clip arms are inserted into the slots. Once fullyinserted into the slot 109, the catch 107 will clip over a surface ofthe body 43 adjacent the slot to secure the casing members 41 together.It will be understood that the clip arms 103 could have otherconfigurations without departing from the scope of the disclosure.Additionally, the casing members 41 could be attached to each other inother ways without departing from the scope of the disclosure. Moreover,other suitable configurations for the casings 33 and other means formounting the conductors 30 in the enclosure 22 may also be incorporatedwithout departing from the scope of the disclosure.

Referring to FIG. 3 , the conductor assembly 26 is formed by receivingthe conductor 30 between two casing members 41 and securing the casingmembers together around the conductor. The central conductor portion 35of the conductor 30 is received in the longitudinal channels 91 of thecasing members 41 and a branch member 36 of the conductor is received inthe transverse channels 99. The longitudinal channels 91 together mayform a longitudinal passage for receiving the central conductor portion35, and the transverse channels 99 together may form a transversepassage for receiving the branch member 36. To align the casing members41 with respect to each other for attaching the casing members together,the hole alignment structures 73, 79 on the inner surface 55 of thecasing members are aligned and engaged with each other to guide thecasing members into secured engagement. In one embodiment, the thirdhole alignment structures 73 around the left two holes 59 of a firstcasing member 41 are mated with the fourth hole alignment structures 79around the right two holes of a second casing member 41. In particular,the annular projection 75 of the third hole alignment structure 73 isinserted between the first and second annular projections 81, 83 of thefourth hole alignment structure 79 and seated on the floor 85 betweenthe first and second projections. The first annular projection 81 of thefourth hole alignment structure 79 will simultaneously seat on thecounterbore of the third hole alignment structure 73. Upon the seatingof the annular projections 75, 81, 83, the clip arms 103 will be fullyinserted into the slots 109 whereby the catches 107 will clip over thesurface of the body 43 adjacent the slots and secure the casing memberstogether. As a result, the conductor 30 will be securely held within thecasing 33 formed by the two casing members 41. For example, the surfacesof the longitudinal channels 91 will engage at least a section of thecentral conductor portion 35 to hold the central conductor in place. Theclamps 101 in the transverse channels 99 will engage the branch member36 to secure the branch member in place. More particularly, the clamps101 will engage the covers 40 of the branch members 36 to prevent thecovers from sliding. In instances where the branch members 36 and/orflexible central conductor portion 34 are not previously attached to therigid central conductor portion 35, the attachment of the casing members41 to each other may also attach the conductor portions together. Thetransverse channels 99 may also provide an open space for the ends ofthe branch members 36 that are not attached to switching apparatuses tobe folded back and inserted into the casing so that the exposed ends 44are shielded by the casing to prevent contact with a user. Thisarrangement is shown in FIGS. 6 and 7 . In one embodiment, the free endsof the branch members 36 are retained in the transverse channels 99 by apress fit. Alternatively, slots 112 in a mounting plate 114 of theenclosure 22 may receive the exposed ends 44 of the branch members 36that are not connected to circuit breakers 32 to insulate the ends ofthe branch members from a user (FIG. 2C).

Two or more casings 33 can also be connected to each other in a linearfashion as shown in FIGS. 3 and 6 . For example, the extension sections47 of the casing members 41 of a first casing 33 are received in a topend of a second casing 33, between the two casing members that form thesecond casing to connect the first casing to the top of the secondcasing. The shoulder 53 between the first and second extension portions49, 51 of the extension sections 47 of the first casing 33 will seatagainst stops 115 on the inner surfaces 55 of the casing members 41 ofthe second casing 33 to properly position the first casing in the secondcasing. With the extension members 47 of the first casing 33 between thecasing members 41 of the second casing 33, when the casing members ofthe second casing are secured together, the first casing will becaptured between the casing members of the second casing therebyconnecting the first and second casing together. Overlapping the casings33 in this manner further ensures that creepage and clearancerequirements are met by insulating the intersection between the casings.This process can be repeated to connect any desired number of casings 33together. The casings 33 could also be connected to each other in otherways without departing from the scope of the disclosure.

Two or more casing 33 can also be connected to each other in a stackedconfiguration as shown in FIGS. 3 and 6 . For example, the second holealignment structure 67 of the bottom two holes 59 on the outer surface57 of a bottom casing member 41 of a first casing 33 can be mated withcorresponding first hole alignment structure 61 of the top two holes 59on the outer surface 57 of a top casing member 41 of a second casing 33to stack the first casing on top of the second casing. In particular,the annular projection 69 of the second hole alignment structure 67 willbe received in the counterbore hole 59 of the first hole alignmentstructure 61 such that the annular projection seats on the flat-bottomhole section 65, and the annular projection 63 of the first holealignment structure is received in the annular recess 71 of the secondhole alignment structure thereby at least temporarily holding thecasings 33 in place on each other. A fastener can then be insertedthrough at least one of the holes 59 to secure the casings 33 to theenclosure 22 and thereby to each other. This will also slightly staggeror offset the first and second casings 33 whereby the second casing willextend below the first casing, and the first casing will extend abovethe second casing. Therefore, the branch member 36 associated with thefirst casing 33 will be offset from the branch member 36 associated withthe second casing 33 which allows for the use of multiple phases in theconductor assembly 26. This process can be repeated to stack any desirednumber of casings 33 on top of each other. The casings 33 could also bestacked on top of each other in other ways without departing from thescope of the disclosure.

The ability to link multiple casing 33 together in a linearconfiguration, as well as the ability to stack multiple casing on top ofeach other configures the power distribution assembly 20 for deliveringmultiple phases of electricity. In particular, multiple conductors 30can be mounted in the enclosure 22 and separated by the insulatingcasings 33 to provide for the delivery of multiple phases ofelectricity. Thus, a first conductor 30 may be configured to distributea first phase of electricity to a first set of switching apparatuses 32in the enclosure 22, a second conductor 30 may be configured todistribute a second phase of electricity to a second set of switchingapparatuses 32 in the enclosure, and a third conductor 30 may beconfigured to distribute a third phase of electricity to a third set ofswitching apparatuses 32 in the enclosure. The casings 33 and insulatingcovers 40 insulate each conductor from the other conductors of theconductor assembly 26 allowing the conductors 30 to be stacked on top ofeach other without having any interference between the phases. Thus, thecasings 33 prevent phase-to-phase shorting when the conductors 30 arestacked on top of each other. It is envisioned that the conductorassembly 26 could have a different number of conductors 30 fordistributing a different number of phases of electricity withoutdeparting from the scope of the disclosure.

Having described the invention in detail, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

As various changes could be made in the above constructions and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description and shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. An electrical conductor assembly for use in apower distribution assembly comprising: an electrical conductorincluding a main conductor portion and at least one branch memberextending laterally from the main conductor portion; and a casingcovering at least a portion of the electrical conductor, the casinginsulating said at least a portion of the electrical conductor, thecasing including a first passage for receiving the main conductorportion and a second passage for receiving the at least one branchmember; and a clamp disposed in the second passage and configured toengage the at least one branch member.
 2. The conductor assembly ofclaim 1, wherein the casing is rigid.
 3. The conductor assembly of claim1, wherein the electrical conductor comprises a flexible electricalconductor including the main conductor portion comprising electricallyconductive material, and the at least one branch member comprisingelectrically conductive material, the branch member being selectivelybendable and configured for electrical connection to an electricalswitching apparatus.
 4. The conductor assembly of claim 3, wherein theelectrically conductive material of the at least one branch membercomprises multiple layers of laminated conductive material.
 5. Theconductor assembly of claim 3, further comprising insulation disposedaround the at least one branch member.
 6. The conductor assembly ofclaim 5, wherein the insulation is disposed around only a portion of theat least one branch members such that a free end of the at least onebranch member is exposed and free of insulation.
 7. The conductorassembly of claim 6, wherein the free end of the at least one branchmember is configured to be folded back into the second passage to shieldthe free end within the casing.
 8. The conductor assembly of claim 1,wherein the casing comprises first and second casing members attached toeach other.
 9. The conductor assembly of claim 8, wherein the first andsecond casing members each have mating alignment structure to properlyposition the casing members relative to each other for attaching thecasing members to each other.
 10. The conductor assembly of claim 1,wherein the casing defines at least one hole for receiving a fastener tomount the conductor assembly in an enclosure.
 11. The conductor assemblyof claim 1, wherein the casing has alignment structure for attaching thecasing to another casing in a linear fashion such that extensionsections on casing members of the casing are received in a top end ofsaid another casing, between two casing members forming said anothercasing, to connect the casing to the top of said another casing.
 12. Apower distribution assembly comprising: an enclosure; a flexibleelectrical conductor disposed in the enclosure, the flexible electricalconductor comprising a single main conductor portion comprisingelectrically conductive material and a plurality of branch memberscomprising electrically conductive material extending laterally from themain conductor portion, each branch member being selectively bendableand configured for electrical connection to an electrical switchingapparatus; and a plurality of casings covering portions of the flexibleelectrical conductor, each casing insulating a portion of the flexibleelectrical conductor, each casing including a first passage forreceiving the single main conductor portion and a second passage forreceiving one of the branch members.
 13. The assembly of claim 12,wherein each casing is rigid.
 14. The assembly of claim 12, wherein theassembly is configured to distribute multiple phases of electricity. 15.A casing for use with an electrical conductor comprising: a first casingmember configured to cover at least a first portion of the electricalconductor; and a second casing member attachable to the first casingmember and configured to cover at least a second portion of theelectrical conductor, the first and second casing members insulatingsaid at least the first and second portions of the electrical conductor,the first and second casing members each including a first passage forreceiving a main conductor portion of the electrical conductor and asecond passage for receiving a branch member extending from the mainconductor portion, and a clamp disposed in the second passage andconfigured to engage the branch member.
 16. The casing of claim 15,wherein the first and second casing members are rigid.
 17. The casing ofclaim 15, wherein the first and second casing members each have matingalignment structure to properly position the casing members relative toeach other for attaching the casing members to each other.
 18. Thecasing of claim 15, wherein the first and second casing members eachdefine at least one hole for receiving a fastener to mount the casing inan enclosure.